SECTION X TOOLS/PUBLICATIONS - Vintage Sno · · 2010-01-20c SECTION X TOOLS/PUBLICATIONS ......

c SECTION X

TOOLS/PUBLICATIONS

Contents of this Section

Special Service Tools . . . . . . . . . . . . 1 - 1 h

Publications - Technical Service Training Material . 2 - 3

Glossary . . . . . . . . . . . . . . . . . 4 - 7

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Ski Alignment Bar

For spindle alignment primarily on I FS models Alignment Bar Specifications:

Material: C-1018 Diameter: .623"-.625" Length: 42"

Not available through Polaris

PN 2870335 - Multitester

Tests all electrical circuits and components

PN 2870459 - Ignition Timing Dial Indicator 0- 1" Range

Indicates piston BTDC position for timing all engines

PN 2870466 - Continuity Light

Checks electrical circuit continuity, breaker point timing and doubles as a flashlight

TOOLS/PUBLICATIONS

Special Service Tools

X - l 5/83

TOOLS/PUBLICATIONS


PN 2870422 - CDI Timing Fixture

Increases timing accuracy on EC34PT, EC44PT 1978 - 1980 TX, TX-C engines

PN 2870159 - Flywheel Puller

Used on all models except those requiring the 2870477 puller listed below PN 3080706 - Replacement Bolts

PN 2870477 -./. Flywheel Puller Pulls flywheels on 34PT, 44PT 1978 - 1980 TX, TX-C and all 34PL engines PN 3080706 - Replacement Bolts

PN 2870336 - Strap Wrench PN 2870389 - Replacement Strap Aids in the removal and installation of flywheels, drive clutches and other cylindrical objects which need holding or turning

5/83

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PN 2870203 - Chain Wrench Holds flywheel puller on 3 cylinder engines and aids in removal and installation of drive clutches, etc.

PN 2870386 - Piston Pin Puller Removes piston pins on all engines

PN 2870390 - Piston Support Block Supports pi ston and prevents pi st o n sk irt damage during cylinder installation on all engines

PN 2870303 - Ammco Model 3950 Cyl inder Hone Rigid cylinder hone for deglazing and truing heat

distorted cylinders 1 7/8" - 2 3/4" Range

TOOLS/PUBLICATIONS


x - lb 5/83

TOOLS/PUBLICATIONS


Replacement Ammco Hone Stone Sets

Cylinder Hone Stone Set Std. Fine (Ammco No. 3952) - PN 2870305

Cylinder Hone Stone Set Std. Coarse (Ammco No. 3951) - PN 2870304

Cylinder Hone Stone Set O.S. Fine (Ammco No.

3954) - PN 2870307

Cy linder Hone Stone Set O.S. Coarse (Ammco No.

3953) - PN 2870306

O.S. Stone Sets Range 2 1/2" - 3 3/8"

PN 2870588 - A mmco 3880 Honing Oil

Improves hone operation and prevents stone loading

PN 2870569 - Crankshaft Alignment Kit

Used for checking and straightenir19 I!rankshafts on all Polaris engines

PN 2870509 - Uni-Syn Gauge

Used to synchronize carburetor air flow on multi

carburetor engines

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PN 2870030 - Steel Drive Clutch Puller

Removes all Polaris steel drive clutches from eng ines 1965-1971

PN 2870130 - Aluminum Drive Clutch Puller

Removes all aluminum drive clutches from engines

PN 2870506 - T Handle Drive Clutch Puller Quick aluminum drive clutch removal for most models

PN 2870461 - Drive Clutch Holding Fixture

PN 2870547 - Electric Start Version PN 5130518 - Replacement Holding Tabs

Used for disassembly of all aluminum drive clutches

TOOLS/PUBL ICATIONS


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TOOLS/PUBLICATIONS


PN 2870338 - Drive Clutch Spider Nut Driver

For removal and installation of drive clutch spider jam nut on high performance models

PN 2870341 - Spider Removai Tool

Fits all aluminum drive clutch spiders. For removal and retorquing of spider

t>N 2870401 - Spider Roller Centering Punch

PN 2870402 - Shift Weight Spring Pin Punch PN 2870507 - Shift Weight / Roller Pin Punch

PN 2870310 - Roller Pin Gauge Block

Used during removal and installation of spider roller pins in standard aluminum drive clutches

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PN 2870426 - 5/8" Offset Clutch Alignment Tool Establishes correct 5/8" drive/driven clutch offset and alignment

PN 2870161 - 9/16" Offset Clutch Alignment Tool Establishes correct 9/16" drive/driven clutch offset and alignment

PN 2870576 - Drive Clutch Bore Tapered Reamer Cleans up all drive clutch bore tapers to ensure proper fit to engine crankshaft

PN 2870399 - Jackshaft Alignment Tool Ensures correct jackshaft bearing alignment during chaincase installation

TOOLS/PUBLICATIONS

Specic;! Service T oob

X-1f 5/83

TOOLS/PUBLICATIONS

SpecialServ ice Tools

PN 2870354 - Suspension Compression Tool Assists with necessary compression of rear suspension springs and shocks to permit tunnel mounting bolt installation

PN 2870380 - IDL Track Clipping Tool Used for installation of all rubber track clips PN 7515461 - Replacement allen head guide bolt

PN 2870623 - Shock Absorber Spring Compression Tool

PN 2870630 - COl Strobe Timing Light High intensity strobe, works on all types of ignition systems including the difficult to time 3 cyls. Self contained Requires no outside power source (Two "0" cell batteries included)

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PN 2870672 - Carburetor Synchronizing Manometer Accurate synchronization of multi carbureted engines which are equipped with vacuum spigots

PN 2870702 - Transmission Seal/Bearing Driver For installing bearings and case seals during transmission gearcase overhaul

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TOOLS/PUBLICATIONS

Technical Service Training Material

5/86

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991 1269

9911283

9911210

9911229

9911227

9911219

9911281

9911288

TOOLS/PUBLICATIONS

Technical Service Training Material

RECOMMENDED SHOP SUPPLIES/ACCESSORIES

Description

Ammco 3880 Honing Oil

Chaincase Oil - One Gallon

Chaincase Oil Pump

Low Temp Grease - 14Y:. Oz. Cartridge

Clutch and Control Cable Lubricant

Fuel System Deicer (Isopropyl)

Loctite Primer T - 6 Oz. Aerosol

Loctite RC 680 - 10cc Retaining Compound

Loctite 515 Gasket Eliminator - 50cc Tube

Loctite/Chisel Gasket Remover - 18 Oz.

Metal Pol ish - 8 Oz.

Dot 5 Si licone Brake Fluid

TECHNICAL SERVICE PUBLICATIONS

Description

Part Number

2870588

2870464

2870465

2870577

2870510

2870505

2870585

2870584

2870587

2870601

2870632

2870381

1987 Master Repai r Manual Update Packet - Includes all service information and specifications pertinent to the 1987 models. Individua l pages are numbered by sections for placement in to the Master Repair Manual

1987 Technica l Service Data Wallcharts Packet

1987 Star, Sprint, Sprint ES Operators Manual

1987 Star Trak Operators Manual

1987 Long Track, Long Track Reverse Low Range Operators Manual

1987 Indy Tra il, 400, 600 Operators Manual

1987 Indy Trail, 400 133-SKS Operators Manual Supplement

Serviceman's Handbook - Quick Reference Spec Book - 1968 - 1987

X-2 5/86

TOOLS/PUBLICATIONS

Publications

TECHNICAL SERVICE TRAINING MATERIAL

Part Number

991 1284

9911092

9910948

9910902

9910431

9910432

9911285

9911286

9911287

Description

Polaris Master Repair Manual Reprint - I neludes all service information and important specifications such as ignition, carburetion, elutch data, etc., from 1972 through 1987. Its looseleaf design enables additions and updates to be made on a continuing basis.

1986 Master Repair Manual Update Packet



Polaris Service Manual Binder - Contains all shop manuals from 1974 through 1978

Service and I nformation Bulletin Package - Complete set of recent service and information bulletins

150- Mile Initial Maintenance Inspection Forms (Package of 25)

1000-Mile Extended Maintenance Inspection Forms (Package of 25)

2000-Mile Extended Maintenance Inspection Forms (Package of 25)

OPERATORS MANUALS AND PART NUMBERS

5/86

9911076 9911087 9911082 9910929 9910937 9910938 9910837 9910838 9910842 9910836 9910786 9910787 9910788 9910820 9910789 9910752 9910751 9910750 9910753 9910765 9910678 9910677 9910681

1986 Star, Sprint, SS Operators Maintenance and Safety Manual 1986 Long Track Operators Maintenance and Safety Manual 1986 Indy Trail, 400, 600, 600 LE Operators Maintenance and Safety Manual 1985 Star - SS Operators Maintenance and Safety Manual 1985 Long Track Operators Maintenance and Safety Manual 1985 Indy Trail, 400, 600 Operators Maintenance and Safety Manual 1984 Star/SS 1984 Long Track 1984 Indy 600/Trail 1984 Indy 400 1983 Star, Sport, SS 1983 Gemini 1983 Indy Series 1983 Long Track 1983 French 1982 Cutlass SS Owners Manual 1982 TX-C Owners Manual 1982 TX-L Owners Manual 1982 TX-L Indy, Centurion Indy Owners Manual 1982 French Owners Manual

1981 Gemini Owners Manual 1981 Galaxy Owners Manual 1981 Cutlass, Cutlass SS Owners Manual

X-2a

OWNERS MANUALS

Part Number

9910680

9910679 9910682

9910683

9910684 9910607 9910608 9910609 9910610

9910611

9910612

9910613

9910547

9910550

9910562

9910554

9910555

9910578

9910433

9910436

9910437 9910438

9910442

9910394

9910414

9910424

9910425 9910333 9910383 9910388 9910375 9910393

9910293 9910264 9910344

9910346

9910224

9910224

9910163

9910163

9910206

9910130

9910130

SHOP MANUALS

Part rllumber

9910513

9910415

9910379

9910307

9910263

9910226

9910262 9910167

TOOLS/PUBLICATIONS

Description

1981 TX-C Owners Manual

1981 TX-L Owners Manual 1981 TX-L Indy, Centurion Indy Owners Manual

1981 French Gemini, Galaxy, Cutlass, Cutlass SS Owners Manual

1981 French TX-C, TX-L, TX-L Indy, Centurion Indy Owners Manual 1980 Gemini, Apollo Owners Manual 1980 Galaxy Owners Manual 1980 TX, TX-C Owners Manual 1980 TX-L, Centurion Owners Manual

1980 TX-L Indy Owners Manual

1980 French Gemini, Apollo, Galaxy Owners Manual

Pu bl ications

1980 French TX, TX-C, TX-L, Centurion, TX- L Indy Owners Manual

1979 Gemini, Apollo, Cobra Owners Manual

1979 TX Owners Manual

1979 TX-C Owners Manual 1979 TX-L, Centurion Owners Manual

1979 French Gem ini, Apollo, Cobra Owners Manual

1979 French TX, TX- C, TX- L, Centurion Owners Manual

1978 Colt, SIS 340 Owners Manual

1978 Cobra Owners Manual

1978 TX Owners Manual

1978 TX- L Owners Manual

1978 French Owners Manual 1977 Colt, Colt SS, Electra Owners Manual

1977 TX Owners Manual 1977 TX-L Owners Manual

1977 French Owners Manual 1976 Colt, Colt SS, Electra Owners Manual

1976 TX Owners Manual 1976 Starfire Technical Owners Manual 1976 French Owners Manual 1976 French TX Owners Manual 1975 Colt, Colt SS, Electra, TX Owners Manual

1975 TC Owners M<lnual 1975 TX Modification Manual

1975 French Owners Manual

1974 Owners Manual


1973 Owners Manual

1973 French Owners Manual 1973 TX Starfire Owners Technical Manual

1972 Owners Manual


Description

1978 Shop Manual

1977 Shop Manual

1976 Shop Manual

1975 Shop Manual 1975 TC Shop Manual

1974 Shop Manual

1974 TX Shop Manual Supplement 1973 Shop Manual

TOOLS/PUBLICA TlONS

Glossary

Air Gap Spark Test:

Alternator:

BTDC:

COl:

Center Distance:

Chain Pitch:

Clutch Buttons:

Clutch Offset:

Clutch Weights:

Coil:

Condenser/Capacitor:

Crankshaft Run-Out:

Detonation:

Dial Bore Gauge:

E. T. Ignition:

Effective Compression

Ratio:

Electrical Open :

5/82

A good check for ignition voltage and general ignition system condition . Spark should

arc 3/8" minimum from end of high tension lead to ground {several testers are available! .

Electrical generator producing voltage alternating current.

Before top dead center.

Capacitor discharge ignition . I gnition system which stores voltage generated by the stator

plate exciter coil in a capacitor or condenser (in COl box ). At the proper mom ent a voltage, generated by the stator plate pulser coil, closes an elec t ronic switch (thyristor)

in the COl box and allows the voltage in the capacitor to discharge into the p rimary

windings of the ignition coil.

Distance between center of crankshaft and center of driven c lutch shaft.

Distance between chain I ink pins (No. 35 = 3/8"). Polaris measures chain length in

number of pitches; i.e., Colt 250 uses 86 pitch chain.

Plastic bushings which transmit rotation of the clutch to the movable sheave in the

drive and driven clutch.

Drive and driven clutches are offset so that drive belt will stay nearly straight as it

moves along the clutch face.

Three levers in the drive clutch which, relative to their weight, profile, and engine RPM,

cause the drive clutch to close.

A winding of wire around an iron core which has the ability to generate an electrical

cu rrent when a magnetic current passes through it.

A storage reservoir for electricity, used in both E. T. and COl systems.

Run-out or "bend" of crankshaft measured with a dial indicator while crankshaft is

supported between centers on V blocks or resting in lower half of crankcase. Measure at various points especially at PTa (.006 maximum run-out is allowable)'

The spontaneous ignition of the unburned fuel/air mixture after normal spark ignition . Piston looks "hammered" through, rough appearance around hole. Causes: 1) too high a compression ratio for the fuel octane; 2) low octane fuel; 3) over· advanced ignition

timing.

A cylinder measuring instrument which uses a dial indicator. Good for showing taper

and out-of-round in the cylinder bore.

Energy transfer ignition . Magneto type ignition system using an external ignition coil.

Compression ratio measured from after the piston closes the exhaust port.

(Open circuit) An electrical circuit which isn't complete.

Example: Poor connections or broken wire at hi-Io beam switch. Re~ult: No head lights.

X-4

Electrical Short:

End Seals:

Engagement RPM:

Foot Pound:

g.:

Head Volume:

Heat Exchanger:

Hi-fax:

High Tension Wire:

Holed or Vented Piston:

Ignition Coil:

Ignition Generating Coil:

Inch Pound:

Kg/cm 2 :

Keystone Ring:

Kilogram/meter:

L Ring:

Labyrinth Seal:

Lighting Coil:

mm:

TOOLS/PUBLICATIONS

Glossary

(Short circuit) An electrical circuit which is completed before the current reaches the

intended component. Example: A bare wire touching the snowmobile chassis under the seat. Result: No taillights or brake lights.

Rubber seals at each end of the crankshaft.

Engine RPM at which the drive clutch engages to make contact with the drive belt.

Ft./lb. or Ib./ft. A force of one pound at the end of a lever one foot in length, applied in a rotational direction.

Gram. Unit of weight in the metric system.

Cylinder head capacity in cc, head removed from engine with spark plug installed.

A device used to transfer heat. The TX-L uses two heat exchangers mounted under the running boards. They, in turn, dissipate engine heat to the atmosphere.

The special slide material which fits onto the bottom of the suspension rails.

The heavy insulated wire which carries the high secondary voltage from the coil to the spark plug.

Piston which a hole has formed on the dome. Causes: 1) detonation; 2) pre-ignition.

A type of transformer which increases voltage in the primary windings (/I..-" 200 V) to a higher voltage in the secondary windings (/"/ 14KV - 32KV) through induction. Secondary voltage is high enough to arc the air gap at the spark plug.

(Exciter coil, primary charge coil) Stator plate coil which generates primary ignitIOn voltage. COl system uses one ignition generating coil. Twin cylinder E.T. ignition systems use two ignition generating coils. Coil is mounted at the top of the stator plate.

12 in./lbs. = 1 ft./lb.

Kilograms per square centimeter.

A piston ring with bevel on upper inside surface.

A force of one kilogram at the end of a lever one meter in length, applied in a rotational direction.

A wide face piston ring with an "L" shaped cross section. (Leg of "L" goes up when installing on piston.)

A pressure-type center seal identified by series of grooves and lands. Polaris engines use this type of seal to separate the cylinders in the crankcase halves.

Large coil mounted at the bottom of the stator plate. Generates voltage for lights, battery charging, etc.

Millimeter. Unit of length in the metric system. 1mm = .040".

X-5

TOOLS/PUBLICATIONS

Glossary

Magnetic Induction:

No.1 Cylinder:

No. 2 Cylinder:

Ohm:

Piston Clearance:

Piston Erosion:

Pre-ignition:

Primary Circuit:

Primary Clutch:

Primary Compression:

psi.:

R& R:

RFI:

RPM:

Resistance:

Right Side & Left Side:

Running Timing:

Secondary Circuit:

Secondary Clutch:

Seized Piston:

As a conductor; i.e., coil, is moved through a magnetic field, a voltage will be generated in the windings. This is how mechanical energy in our engines is converted to electrical energy in the lighting coil, ignition generating coils and trigger coil.

Cylinder on flywheel side of engine.

Cylinder on PTO side of engine.

(.1l.) The unit of electrical resistance opposing current flow.

Total distance between piston and cylinder wall.

Piston dome melts. Usually occurs at the exhaust port area. Causes: Lean fuel/air mixture, improper spark plug heat range.

A problem in combustion where the fuel/air mixture is ignited before normal spark ignition. Piston looks melted at area of damage. Causes: 1) too hot a spark plug; 2) spark plug not properly torqued; 3) "glowing" piece of head gasket, metal burr, or carbon in the combustion chamber; 4) lean fuel/air mixture.

This circuit is responsible for the voltage build-up in the primary windings of the coil. Parts of this circuit include the exciter coil, points and condenser, wires from the stator plate to the small primary winding in the ignition coil. In the COl system the parts include the exciter coil, the trigger coil, the wires from stator plate to COl box and to the low resistance primary windings in the ignition coil.

Drive clutch on engine.

Pressure built up in the crankcase of a two stroke engine.

Pounds per square inch.

Remove and replace.

Radio frequency interference. Caused by high voltage from the ignition system. There are special plug caps and spark plugs to help eliminate this problem. (Required in Canada.)

Revolutions per minute.

In the mechanical sense, friction or load. In the electrical sense, ohms. Both result in energy conversion to heat.

Always referred to based on normal operating position of the driver.

Ignition timing when fully advanced or at specified RPM.

This circuit consists of the large secondary coil windings, high tension wire and to ground through the spark plug air gap.

Driven clutch on chaincase or jackshaft

Galling of the sides of a piston. Usually there is a transfer of aluminum from the piston onto the cylinder wall. Causes: 1) improper lubrication; 2) excessive temperatures; 3) insufficient piston clearance; 41 stuck piston rings.

X-6

Spark Plug Reach:

Static Timing:

Stator Plate:

Surge Tank:

TDC:

Transfer:

Trigger Coil:

ACV:

DCV:

V Regulator:

Venturi:

Volt:

Watt:

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TOOLS/PUBLICA TlONS

Glossary

Length of thread portion on spark plug. Polaris uses 3/4" reach plugs.

Ignition timing when engine is at zero RPM.

The plate mounted under the flywheel supporting the primary ignition components and

lighting coil.

The fill tank in the liquid cooling system.

Top dead center. Piston's most outward travel from crankshaft.

The movement of fuel/air from the crankcase to the combustion chamber in a two

stroke engine.

(Pulser coil) Generates the voltage for triggering (closing) the thyristor and timing the spark in COl systems. Small coil mounted at the top of the stator plate next to the ignition generating coil.

Alternating current voltage.

Direct current voltage.

Voltage regulator. Maintains maximum lighting coil output @...t'-"14.5 ACV as engine RPM increases.

An area of air constriction. A venturi is used in carburetors to increase velocity pr ssure (speed up air flow) which decreases static pressure (lowers pressure in venturi to low atmospheric pressure) causing fuel to be pushed through jets, etc., and into the venturi to be mixed with air and form a combustible air/fuel mixture.

The unit of measure for electrical pressure or electromotive force. Measured by a Voltmeter in parallel with the circuit.

The unit of electrical power. Watts = Amperes x Volts.

X-7

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SECTION X TOOLS/PUBLICATIONS - Vintage Sno · · 2010-01-20c SECTION X TOOLS/PUBLICATIONS ......

Documents

Transcript of SECTION X TOOLS/PUBLICATIONS - Vintage Sno · · 2010-01-20c SECTION X TOOLS/PUBLICATIONS ......